Information injection-pump assembly
BOSCH
9 400 616 023
9400616023
ZEXEL
101692-3032
1016923032
KOMATSU
6206711220
6206711220
Rating:
Service parts 101692-3032 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 616 023
9400616023
ZEXEL
101692-3032
1016923032
KOMATSU
6206711220
6206711220
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
31.8
30.8
32.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.5+-0.
5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9.5
11.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK CAP: R1
(3)The torque control spring must does not have a set force.
(4)Rack difference between N = N1 and N = N2
----------
K=8 R1=(17.5)mm N1=1100r/min N2=700r/min
----------
----------
K=8 R1=(17.5)mm N1=1100r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=(7deg)+-5deg b=32deg+-3deg c=21deg+-5deg
----------
----------
a=(7deg)+-5deg b=32deg+-3deg c=21deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Use fuel consumption or service hours, whichever occurs first, to determine maintenance intervals. Experience has shown that maintenance intervals are most accurately scheduled on the basis of fuel consumed rather than service hours.Daily
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Clutch - Check/Adjust/Lubricate Air Starter & Air Tank (if equipped) - Check Engine Air Cleaner - Check service indicator SR4 Generator - Inspect/CheckEvery 1,900 L (500 gal) of Fuel or 50 Service Hours*
Dust Collector - Clean Light Duty Air Cleaner (If Equipped) - ReplaceEvery 4,250 L (1,100 gal) of Fuel or 125 Service Hours*
Clutch - Check/Adjust/Lubricate Generator Space Heaters - CheckEvery 8,500 L (2,200 gal) of Fuel or 250 Service Hours*
Scheduled Oil Sampling (S O S)1 - Obtain Sample Engine Oil and Filter(s)1 - Change Crankcase Breather1 - Clean Engine Valve Lash (Between First 250 and 1000 Service Hours Only)1 - Check/Adjust Cooling System - Test for supplemental coolant additive concentration Fuel System - Clean/Replace filters, Drain water from fuel tank Radiator Fins, Aftercooler, Belts, and Hoses - Inspect/Check Fan Drive Bearing - Lubricate Batteries - Clean/Check Magnetic Pickup (At First Oil Change Only - Inspect/Clean1These maintenance requirements are to be performed between the 250 and the 1000 Service Hour interval for engines equipped with turbochargers (T, TA & ATAAC) ONLY. Refer to 500 Hour interval for Naturally Aspirated (NA) Engines.Every 17,000 L (4,500 gal) of Fuel or 500 Service Hours (NA Only)*
Scheduled Oil Sampling (S O S) - Obtain Sample Engine Oil and Filter(s) - Change Crankcase Breather - Clean Engine Valve Lash (Between First 500 and 1000 Service Hours Only) - Check/AdjustEvery 34,000 L (9,000 gal) of Fuel or 1000 Service Hours*
Engine Protection Devices - Inspect SR4 Generator and Control Panel - Inspect Fuel Control Linkage - LubricateEvery 67,000 L (18,000 gal) of Fuel or 2000 Service Hours*
Engine Valve Lash, Valve Rotators, Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust Fuel Injection Nozzles - Test/Clean/Replace Turbocharger - Inspect Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect SR4 Generator - Check/Inspect Clean/LubricateEvery 91,000 L (24,000 gal) of Fuel or 3000 Service Hours or Two Years*
Cooling System - Add Extender (Extended Life Coolant Only) - Cooling System - Drain/Clean/Replace Coolant - Conventional Coolant/Antifreeze Only Water Pump Seal - Inspect/Replace Hoses - Replace Thermostat - ReplaceEvery 136,000 L (36,000 gal) of Fuel or 4000 Service Hours*
Magnetic Pickup - Inspect/Clean SR4 Generator - Check/Inspect/Clean/LubricateEvery 204,000 L (54,000 gal) of Fuel or 6,000 Service Hours or Four Years
Cooling System - Drain/Flush/Replace Coolant (Extended Life Coolant Only)*Perform previous maintenance interval items first.
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Clutch - Check/Adjust/Lubricate Air Starter & Air Tank (if equipped) - Check Engine Air Cleaner - Check service indicator SR4 Generator - Inspect/CheckEvery 1,900 L (500 gal) of Fuel or 50 Service Hours*
Dust Collector - Clean Light Duty Air Cleaner (If Equipped) - ReplaceEvery 4,250 L (1,100 gal) of Fuel or 125 Service Hours*
Clutch - Check/Adjust/Lubricate Generator Space Heaters - CheckEvery 8,500 L (2,200 gal) of Fuel or 250 Service Hours*
Scheduled Oil Sampling (S O S)1 - Obtain Sample Engine Oil and Filter(s)1 - Change Crankcase Breather1 - Clean Engine Valve Lash (Between First 250 and 1000 Service Hours Only)1 - Check/Adjust Cooling System - Test for supplemental coolant additive concentration Fuel System - Clean/Replace filters, Drain water from fuel tank Radiator Fins, Aftercooler, Belts, and Hoses - Inspect/Check Fan Drive Bearing - Lubricate Batteries - Clean/Check Magnetic Pickup (At First Oil Change Only - Inspect/Clean1These maintenance requirements are to be performed between the 250 and the 1000 Service Hour interval for engines equipped with turbochargers (T, TA & ATAAC) ONLY. Refer to 500 Hour interval for Naturally Aspirated (NA) Engines.Every 17,000 L (4,500 gal) of Fuel or 500 Service Hours (NA Only)*
Scheduled Oil Sampling (S O S) - Obtain Sample Engine Oil and Filter(s) - Change Crankcase Breather - Clean Engine Valve Lash (Between First 500 and 1000 Service Hours Only) - Check/AdjustEvery 34,000 L (9,000 gal) of Fuel or 1000 Service Hours*
Engine Protection Devices - Inspect SR4 Generator and Control Panel - Inspect Fuel Control Linkage - LubricateEvery 67,000 L (18,000 gal) of Fuel or 2000 Service Hours*
Engine Valve Lash, Valve Rotators, Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust Fuel Injection Nozzles - Test/Clean/Replace Turbocharger - Inspect Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect SR4 Generator - Check/Inspect Clean/LubricateEvery 91,000 L (24,000 gal) of Fuel or 3000 Service Hours or Two Years*
Cooling System - Add Extender (Extended Life Coolant Only) - Cooling System - Drain/Clean/Replace Coolant - Conventional Coolant/Antifreeze Only Water Pump Seal - Inspect/Replace Hoses - Replace Thermostat - ReplaceEvery 136,000 L (36,000 gal) of Fuel or 4000 Service Hours*
Magnetic Pickup - Inspect/Clean SR4 Generator - Check/Inspect/Clean/LubricateEvery 204,000 L (54,000 gal) of Fuel or 6,000 Service Hours or Four Years
Cooling System - Drain/Flush/Replace Coolant (Extended Life Coolant Only)*Perform previous maintenance interval items first.